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FIRETEX
Firetex
Application and Installation Manual
General Details
Firetex M93
M93
Leighs Paints
Tower Works . Kestor Street . Bolton . BL2 2AL . UK Tel: +44 (0)1204 521771 Fax: +44 (0)1204 382115 e-mail: enquiries@leighspaints.co.uk website: www.leighspaints.co.uk
Application Manual
Issue: 4
Revision: 1
Date: 22/09/09
Firetex M93 is fully tested and certified and while this manual is not intended as a source for the determination of Firetex M93 loadings or other specification criteria, such information is available to design architects and engineers on request.
The information contained in this manual is based upon independent test data, comprehensive research and field experience, and is considered to be accurate at the time of publication. However, the contents will be subject to revision from time to time due to our policy of continuously improving our products, processes and service. Only the electronic copy of this manual is a controlled document and all paper versions are uncontrolled. Thus the user is advised to ensure they have the latest issue of the manual by contacting Leighs Paints International Business Unit. Leighs Paints Tower Works Kestor Street Bolton BL2 2AL
Tel: +44 (0) 1204 521771 Fax: +44 (0) 1204 526452 Email: enquiries@leighspaints.co.uk Web: http://www.leighspaints.co.uk Leighs Paints do not assume responsibility for any direct or consequential damages resulting from the use of Firetex M93 unless expressly agreed in writing Issue No. Rev. No. Date Approved By
22/09/2009
GGB
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2.0 SURFACE PREPARATION AND PRIMING ..................................................................................... 6 2.1 Surface Defect Repair ........................................................................................................................ 6 2.2 Blast Cleaning steel substrates ....................................................................................................... 6 2.3 Repair / Touch - Up ............................................................................................................................ 6 2.3.1 UHP Water Jetting (Hydroblasting) ............................................................................................. 7 2.3.2 Low pressure precision wet blasting. ......................................................................................... 7 2.4 Priming ............................................................................................................................................... 8 2.4.1 Primer Qualification ..................................................................................................................... 8 2.4.2 Zinc Silicate Priming System ....................................................................................................... 9 2.4.3 Over-coating of approved primers with Firetex M93 ................................................................... 9 2.4.4 Application of Firetex M93 to Bare Steel ................................................................................... 10
4.0 APPLICATION ................................................................................................................................. 13 4.1 Application conditions & in process testing ...................................................................................... 13 4.2 Storage ............................................................................................................................................. 15 4.3 Plural Component Application Procedure ........................................................................................ 15 4.3.1 Weight Ratio Checks ................................................................................................................. 16 4.3.2 Spray Tips and Operating Pressure .......................................................................................... 16 4.3.3 Spraying .................................................................................................................................... 16 4.3.4 Flushing of Equipment ............................................................................................................... 17 4.4 Finishing after Spray Application ..................................................................................................... 17
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4.5 Hand Application .............................................................................................................................. 18 4.6 Removal and Repair Procedure ....................................................................................................... 18 4.7 Welding ............................................................................................................................................ 19 4.8 Overcoating ...................................................................................................................................... 19 4.9 Exposed Top Flanges ...................................................................................................................... 20 4.10 Preformed Castings ....................................................................................................................... 20
5.0 COAT BACK .................................................................................................................................... 20 6.0 THICKNESS CONTROL AND MEASUREMENT ........................................................................... 21 6.1 Methods of Measurement ................................................................................................................ 22 6.1.1 Destructive Method.................................................................................................................... 22 6.1.2 Non-destructive Method ............................................................................................................ 22 6.2 Calibration of Electromagnetic gauge .............................................................................................. 22 6.3 Frequency of Measurements ........................................................................................................... 23 6.3.1 Structural Steelwork .................................................................................................................. 23 6.3.2 Flat Plate, Decks and Bulkheads .............................................................................................. 23 6.4 Acceptance Criteria .......................................................................................................................... 23 6.5 Reinforcement and DFT Measurement............................................................................................ 24
7.0 TOPCOAT SELECTION .................................................................................................................. 25 7.1 Approved top coats for Firetex M93 ................................................................................................. 25 7.2 Splash Zones and Immersion .......................................................................................................... 25 7.3 Non-Skid Surfaces ........................................................................................................................... 25
APPENDIX 1 - PRIMER QUALIFICATION FORM................................................................................ 26 APPENDIX 2 APPROVED TOPCOATS FOR FIRETEX M93 .............................................................. 27 APPENDIX 3 - FIRETEX M93 REPAIR SKETCH ................................................................................. 28 APPENDIX 4 - PULL-OFF ADHESION TEST PROCEDURE FIRETEX M93 ................................... 29
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APPENDIX 5 TYPICAL TERMINATION DETAILS PIPE SUPPORTS ............................................. 30 5.1 Typical detail for sliding pipe support where top of beam exposed to fire or radiant heat ............... 30 5.2 Typical detail for sliding pipe support where top of beam is not exposed to fire or radiant heat, or is cooled by deluge .................................................................................................................................... 31 5.3 Typical detail for fixed pipe support where top of beam is exposed to fire or radiant heat .............. 32 5.4 Typical detail for fixed pipe hanger .................................................................................................. 33
APPENDIX 6 TYPICAL TERMINATION DETAILS GRATED DECKS .............................................. 34 6.1 Standard detail or protection of top of beam exposed to fire ........................................................... 34 6.2 Alternative detail for heavy duty protection of top of beam exposed to fire ..................................... 35 6.3 Alternative detail for protection of top of beam exposed to fire........................................................ 36 6. 4 Standard detail for unprotected top flange where it is not exposed to Fire and radiant heat, or is cooled by deluge .................................................................................................................................... 37
APPENDIX 7 TYPICAL COATBACK DETAILS ................................................................................... 38 7.1 I-section to I-section with level top flange ....................................................................................... 38 7.2 I-section to I-section within web ...................................................................................................... 39 7.3 CHS to CHS .................................................................................................................................... 40 7.4 I-Beam under plated deck ............................................................................................................... 41
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1.0 Introduction
Firetex M93 is a solvent free, thick film epoxy intumescent coating, providing an uncompromising solution for the fire protection of many different types of structure in the most demanding environments. It is very closely related to Firetex M90, which has been successfully used on over 2000 major projects worldwide. Epoxy intumescent coatings have major advantages in durability, weight, ease of application and aesthetics. As a result they have become the fire protection method of choice and offer design architects and engineers a highly adaptable PFP solution, which is both practical and functional.
To insulate structural steel elements against damage or collapse in a fire, thus maintaining the integrity of the structure and allowing evacuation and fire fighting measures to be effected.
To insulate walls and decks reducing the rate at which these structures weaken or transfer heat. Such divisions are used to isolate accommodation areas and safe havens from production, storage and utility areas, providing the maximum opportunity for escape in the event of fire.
Firetex M93 is designed to protect against the very severe fires that are associated with the combustion of hydrocarbon fuels (oil, methane, LNG, LPG, etc.). Additionally the aggressive production environments normally associated with these industries require Firetex M93 to be extremely durable. Whilst Firetex M93 has excellent durability, it is normal to use a suitable anti-corrosive primer and a good quality topcoat. Mechanical reinforcement may also be required in the form of a specially designed fire resistant scrim. Full details are contained in Section 3.
The aim of this manual is to provide relevant technical information to the applicator of Firetex M93, helping to ensure that the completed project is fit for purpose. Since product failure could threaten life in
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an emergency fire situation, applicators must not deviate from our recommendations without express written agreement from Leighs Paints.
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Alternative methods of surface preparation used in maintenance painting are UHP and Wet Abrasive Blasting. These methods are discussed below:
In practice there is likely to be some flash rusting occurring after UHP preparation has been completed. The maximum degree of flash rusting allowed is that described as Light Flash Rusting (L) in the above BS EN ISO 8501-4 or SSPC/NACE standards. Any loose, powdery flash rust must be removed with a stiff bristle brush.
Since no exact standard exists a reference area should be established to the satisfaction of all interested parties.
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2.4 Priming
It is essential in a fire situation that Firetex M93 remains adhered to the substrate for the duration of the expected protection period. In most cases the substrate will be primed and hence the adhesion of M93 to the primer must be verified. For this reason only primers & coating systems satisfactorily tested and qualified by Leighs Paints shall be used under Firetex M93. The method of primer qualification is the same whether manufactured by Leighs or by other coating companies. Coatings manufacturers are encouraged to seek qualification of their primers for use under Firetex M93 and an overview of the qualification process is given below. Further information is available from Leighs Paints.
A complete, up to date list of qualified primers, both Leighs Paints own products and those of other paint manufacturers, is available from our web site at www.leighspaints.co.uk, or by contacting us. Primer and top coat painting must be carried out in accordance with the appropriate manufacturers technical data sheets. For application of Firetex M93 see section 4 of this manual.
The qualification process is free of charge, requiring the primer manufacturer to provide either a wet sample of the relevant product for us to apply, or a minimum of four plates prepared and coated with the primer as per the relevant site conditions.
In all cases the relevant application form (see Appendix 1) should be completed and sent to Leighs Paints along with either the wet samples or the test plates. A copy of the form may be sent in advance by fax, email or post and contact details are given at the front of this document. Where wet samples are supplied then both the MSDS and Technical Data Sheet for each product MUST be supplied to ensure correct application and safe handling. If the project specified primer DFT is different from that quoted on the technical data sheet, then it is this thickness that should be identified on the application form.
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Where test plates are provided these should be approximately 200mm x 150mm (8 x 6) with a minimum thickness of 3mm (0.12) and preferably 5mm thick (0.2). The use of steel plate thinner than this is likely to give a false fail result when impact tested. The actual thickness of each coat applied to the plates should be identified, since in a multi-coat system we would only be able to confirm the total DFT. If panels are supplied rather than wet paint, then it is strongly recommended that an additional set of four plates be provided with the primer applied at the maximum thickness expected on the project. Otherwise qualification will be restricted to the nominal specified DFT and there will be no scope to accommodate over application on site.
Unless tested and otherwise stated then approvals for all primer systems will be limited to 150 microns DFT (6 mils). For zinc rich epoxy systems a tie coat will be required and total primer/tie-coat thickness will be limited to 125 microns DFT (5 mils).
An application form for primer qualification is included in Appendix 1 and may be photocopied if more than one submission is required.
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3.0 Reinforcement
3.1 Reinforcement Systems
When Firetex M93 reacts in a fire the char developed may need to be reinforced by the incorporation of a high temperature scrim cloth. This is incorporated at the time of application at approximately mid-film depth, depending on type and shape of steel element to be protected. In all instances the substrate must have been prepared in accordance with Section 2. Diagram showing location of high temperature scrim cloth on typical H-section
3-sided beam
Note: For hollow section elements Firetex H180 scrim cloth shall be wrapped fully around the circumference/perimeter with an overlap nominally 50mm (2). FIRETEX M93 High temperature scrim cloth
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Where lengths of Firetex H180 scrim overlap, it is essential to ensure good bonding between layers by fully wetting out the scrim cloth.
Two methods of installation can be used depending on the total film thickness required, the complexity of the job and the applicators preference in terms of number of jobsite visits. A) Apply one coat of Firetex M93 to approximately one half of the total thickness required. While M93 is still wet, install the scrim cloth ensuring it is fully wetted out. Within the same application shift apply a thin coat (typically 1mm (40 mils) but need not be exact) such that the scrim cloth is sealed. Allow to cure sufficiently such that meaningful film thickness measurements can be taken and then apply the final coat to achieve the desired specification thickness.
B) Apply approximately one third of the total thickness of Firetex M93 required and allow to cure sufficiently to take meaningful film thickness measurements. Subsequently apply a thin wet coat (about 1mm (40 mils)) Firetex M93 and then install into this the scrim cloth, ensuring that it is fully wetted out. While still wet apply a further thin coat and allow to cure sufficiently such that meaningful film thickness measurements can be taken. The aim is to get this mid part of the film to be about one third the total required thickness. Finally apply the final coat to achieve the desired specification thickness. Note: Firetex H180 cloth scrim must be installed in the correct direction. The thicker wire strand must run across the flange and around the toe of an H-section. For hollow section, the thicker wire strand must run around the circumference / perimeter of the profile.
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4.0 Application
The Firetex M93 data sheet also contains vital information regarding application parameters and must be read in conjunction with this manual. A copy of the data sheet can be obtained from Leighs Paints or from our web site at www.leighspaints.co.uk. The mixing ratio is 2 parts base to 1 part additive by volume (2:1 by weight), irrespective of pack size.
Firetex M93 can be applied through suitable Plural Component Airless Spray units that utilizes a minimum 10 Air Motor (contact Leighs Paints for a list of suitable equipment) and has a volumetric pumping ratio of 2 :1. Pumps that do not have a 2:1 volumetric ratio must not be adjusted to provide a 2:1 mix by varying the pressure settings. Firetex M93 is supplied in 60kg kits (approx. 132 lbs) for this purpose. Spray machines suitable for the application of Firetex M93 will be provided with instructions from the equipment supplier and these should be consulted to ensure correct machine operation and maintenance. The importance of keeping spray equipment clean and efficient cannot be overstated and for this reason a skilled and experienced machine operator is a vital component of the team It is also possible to hand apply Firetex M93 by trowel or float. The contractor must determine if this is cost effective for larger areas. The practical density of Firetex M93 is 1.1 kg/ltr +/- 0.03% (9.17 lb/USgal) after application by plural component airless spray (for further detail see Technical Data Sheet, available from our web site). The Base component is coloured White and the Additive component is coloured Blue. When correctly mixed a homogeneous Pale Blue colour should be achieved, free from streaks of either white or darker blue. Regular wet film thickness checks should be made during the application process.
The following conditions are the absolute limits under which Firetex M93 shall be applied. Note that the optimum conditions are the preferred application conditions and these are also given below.
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Minimum air temperature: Maximum Relative Humidity: Minimum steel temperature: Maximum Steel Temperature:
The optimum conditions for application and curing of Firetex M93 are: Temperature: Relative Humidity: 10C to 35C (50F to 86 F) <75%
o
If applied in conditions above 35C (95F) and >75% RH, Firetex M93 may exhibit a soft thermoplasticlike effect, which may result in reduced cohesive properties and pull-off adhesion readings. This delayed curing is to be expected and does not reduce the fire protection performance of the product. When ambient conditions return to stated requirements optimum cure will be achieved albeit over an extended period of time.
Under such conditions pull-off adhesion testing is of little use for in-process testing and Shore D Hardness testing is preferred. Shore D testing can be used to monitor the development of cure with time and when a minimum value if 50 has been reached, fire resistance performance will be in-line with certification. Shore D testing shall be done in accordance with ISO 868:2003 using the method of taking the instantaneous maximum reading. At elevated temperatures heat loss along the fluid line will be less and hence it may be necessary to reduce the temperature of the base and additive holding tanks. The spray pump may need to be located in an air-conditioned environment. Hoses should be insulated and wrapped with heat reflecting tape. It may also be necessary to raise hoses above the ground in extremely hot environments. High substrate temperatures should be avoided by providing suitable shade cover and air-conditioning of the area immediately surrounding the workface may also be necessary The warmer the air temperature, the shorter will be the working life after application for trowel and rolling finishing. If pressurized holding tanks are used then a water trap must be installed in the air supply line and an inline air drying cooling system installed. Condensation inside the holding tanks may cause the M93 affect application and curing. When temperatures drop below 10C (50F), curing time will be significantly extended and will effectively cease below 5 C (41 F). If application has to take place under such conditions then appropriate measure must be taken (such as enclosures, heating, dehumidification, etc.) to elevate the temperature of the work-piece, the spray pump, fluid delivery lines and Firetex M93 containers.
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Care must be taken to avoid condensation in the containers and equipment and to ensure the steel substrate meets the above requirements for dew point.
4.2 Storage
For plural component spray application it is strongly recommended that both base and additive are stored at 30C to 35 C (86F to 95 F) until the contents have reached equilibrium with the storage temperature. This would normally take at least 24 hours and is intended to reduce the inherent viscosity of the product facilitating airless spray application. Base and additive containers may be stored under these conditions during the application process but for long term storage it is recommended that the temperature remains within the range 0C (32F) to 25C (77F) but should not go outside the limits of -5C (23F) to +30C (86F), other than for short periods as noted above. Shelf life quoted on the technical data sheet is based on the use by date located in a small rectangular box on the right hand side of the container front label.
o o
Typical temperature settings (varies with ambient temperature): Base 45C to 55 C (113F to 131 F) Additive 45C to 55 C (113F to 131 F) Line heaters (if fitted) 45C to 55 C (113F to 131 F)
o o o o o o
The components should be circulated through the metering cylinders (and line heaters) until the base has reached 45C to 55C (113F to 131 F) and additive has reached 45C to 55 C (113F to 131 F).
o o
Switch on main pump for approximately 10 minutes at an input pressure of 20 p.s.i. Empty a minimum of 20 litres (5 US gal) of base and 10 litres (2.5 US gal) of additive through the sampling valves (if the equipment does not have sampling valves then the hoses before the mixing block should be disconnected). Material should be kept clean and unmixed so that it can be re-used.
Carry out weight ratio check with input pressure on main pump at 30psi (See 4.2.1). If weight ratio check is satisfactory commence spraying.
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Note: The above temperatures and are for guidance and will vary for different spray equipment. Whatever equipment is used, the minimum mixed M93 temperature for good atomisation using a 10-inch motor is in the range 45C to 55C (113F to 131 F).
o
4.3.3 Spraying
It is possible to apply Firetex M93 in one coat to a minimum thickness of 1mm (0.04) and a maximum thickness of 7mm (0.276). This can be achieved in one of two ways:
(a) By applying the M93 as more of a jet than a fan, then smoothing off with a trowel or float prior to rolling, to obtain a smooth finish.
(b) By applying the M93 with a normal spray pattern. It may still be necessary to roller to obtain a smooth finish. This method of application will require the pump to be operating at its maximum working pressure.
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Following spray application of Firetex M93 a trowel should be used to eliminate any voids and then a roller to attain a smooth uniform finish, unless a stipple finish is required. Firetex M93 can be dry rolled without solvent or material pick up. The optimum time will be temperature dependent but for most projects it has been found to be in the region of 10 to 20 minutes after spraying. A medium pile simulated sheepskin roller has been found to give good results but other short or medium nap synthetic rollers may be suitable. It is recommended that suitability of roller be established on a small area prior to use. Spray mist bottle
If preferred, solvent can be used to dampen the roller as per normal site practice for application of epoxy PFP but one must ensure that the roller is suitable for use with
strong solvents. The quantity of solvent used should be kept to a minimum. Although not recommended if a spray mist bottle is a used the mist must be sprayed onto the roller not the substrate. The solvent used should be Leighs Thinner Number C9. Care should be taken to ensure that all residual solvent has evaporated from the film before applying subsequent layer of M93 or topcoat. Failure to do so could lead to solvent entrapment within the film and subsequent coating failure.
All horizontal flat surfaces must be finished to provide a slight incline designed to shed water and prevent pooling.
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Hawk / Board
Gauging Trowel
Plasters Darby
Care should be taken to avoid air entrapment in the M93, and as this is a relatively slow method of application, do not mix more product than can be easily applied within the pot life of M93. If this method is used for large areas then the applicator must be confident that they can manage this within the working pot life.
As with all epoxy products, high temperature will significantly reduce the working pot life.
An alternative and very effective method is the use of Ultra High Pressure (UHP) water jetting. After removal of Firetex M93 prepare the surface to a minimum standard of St.3 (BS.7079 Part A1 1989) (SSPC-SP3), as detailed in Section 2.3, immediately prior to coating. The edges of the repair should be feathered down to the reinforcement (if present) so that the mesh within the repair patch can be overlapped with the existing mesh for a minimum of 50mm (2). Where
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reinforcement (H180 scrim or metal mesh) is not required (e.g. on webs), then clearly there is no need to install reinforcement during any repair of these areas.
4.7 Welding
Welding cannot be carried out in areas previously coated with Firetex M93 until it has been removed. Using one of the methods discussed above remove the Firetex M93 to a distance of at least 200mm (8) in all directions from the point of welding and on both sides of the steel if applicable. In certain instances, it may be necessary to remove more than 200mm (8), and this can be determined at the time of welding by observing any discolouration, blistering or lifting, or excessive softening of the M93. If such defects occur the M93 should be cut away to the point where the defect no longer occurs. It may also be possible to remove less than 200mm (8), on occasions where only small items are being welded onto a main section, but again this can be best determined at the time of welding. If in doubt the temperature of the steel immediately adjacent to the Firetex M93 termination line should not exceed 80 C (176 F) for more than 5 minutes and should not exceed 120 C (248 F) under any circumstances.
o o o o
4.8 Overcoating
Cleaning of contaminated surfaces between coats will be achieved by thorough washing with detergent, followed by rinsing with clean fresh water and drying. If contamination cannot be removed by this method, consult Leighs Paints. The use of solvent to clean between coats is not normally required but may be specified in certain circumstances. Where solvent is specified for cleaning between subsequent coats of Firetex M90 or topcoat care must be taken not to use excessive quantities and this is best achieved by using a clean lint free cloth damped with approved solvent (see under thinning in Section 4.3). Solvent should not be applied directly to the substrate and must be allowed to fully evaporate prior to commencing over coating to avoid solvent entrapment. On occasions it may occur that Firetex M93 has already been top coated when it is subsequently determined that additional M93 is required. In certain cases, depending on the topcoat applied, it may not be necessary to fully remove all the topcoat. In ALL such cases consult Leighs Paints.
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Where the design allows for the omission of fire proofing to the top flange then appropriate procedures must be taken to ensure correct termination of Firetex M93.
Please note, however, that Leighs Paints have data on other coat-back distances and alternative recommendations may be given. These will be project specific and dependent on the view of both the client and the verification society. If distances other than 450mm (18) are considered appropriate then please contact Leighs Paints.
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The proposals given below are those considered appropriate by Leighs Paints, however, where these proposals differ from project requirements, the clients advice must be sought in determining which documentation takes precedence.
Classification & Verification Organisations such as Lloyds Register, Det Norske Veritas, etc. issue certified thickness tables for Firetex M93 and other epoxy PFP products. The values found in these tables are normally defined as minimum thickness. Thus strict interpretation would mean that no area of a PFP project would be allowed to have any thickness below that stated on the certificate. In practice one will always achieve a normal distribution of applied product thickness and attainment of a minimum thickness across all areas of a project is very difficult to achieve in a timely and cost effective manner. Thus one really needs to consider what if any, normal variation may be allowed to take account of the realities of PFP application. In doing this it is necessary to also consider how the certified tables are derived.
The data used to create the certified tables originates from a large number of fire tests on many specimen steel plate and structural section. Each specimen is coated with the fire protection product applied using spray equipment similar to that used on site. Consequently each steel specimen has an inherent normal distribution of applied product thickness, just as it would on a real project. The mean PFP thickness from each of these specimens is used to derive the certified tables of Hp/A against product thickness. From this point onwards the thickness stated becomes a minimum value. Thus one finds inherent variation in the applied product thickness on both the test specimens and on the real project due to the practical nature of the application method. It is also a case that the lower the epoxy PFP thickness the shorter the fire protection time on a given steel section size. Thus recognizing that variation in thickness is inherent in both the original test data and on the real project one needs to define an acceptable limit that can be practically achieved on site but will not compromise product performance and safety. The aim during application should be to control thickness as tightly as possible and achieve a result as close as possible to the design value.
The following proposals for thickness measurement and tolerance are in line with those broadly adopted by the intumescent fire protection industry within the UK civil building sector.
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Magnetic gauges should be capable of providing accurate readings at a thickness in excess of the maximum DFT to be measured. Ideally the gauge should be capable of storing data and determining statistical information (mean, minimum, maximum, etc.).
Calibration should be carried out using the designated smooth steel plate provided with the instrument. Smooth plastic shims specifically designed for calibration and traceable to a national standard must be used. Two shims should be chosen, one having a thickness no more than 50% above the maximum, the other no more than 50% below the minimum of the DFT range to be measured. Gauge accuracy should be determined by measuring, on the smooth steel calibration plate, a further traceable calibration shim of known thickness within the previously calibrated range.
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Firetex M93 DFT should be determined prior to application of topcoat. Failure to do this may require topcoat to be removed should the DFTs prove to be under specification. Where reinforcement is required mid-film, or where more than one coat is to be applied it may be considered appropriate, or dictated by project specification, to measure the Firetex M93 at an intermediate stage. Knowledge of the interim DFT will allow greater control of the subsequent coats of Firetex M93.
6.4.2
Where any single thickness reading is found to be less than 80% of the specified thickness, further readings in the area of the low reading should be taken as follows:
6.4.2.1
Where the web, flange or other face is wide enough then three, nominally equidistant readings should be taken at a distance of 150 - 300mm (6 12) away from the low reading.
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6.4.2.2
Where the web, flange or other face is not wide enough to allow the above, then two nominally equidistant readings should be taken at a distance of 150 - 300mm (6 12) away from the low reading.
6.4.2.3
For CHS, 2 additional readings should be taken nominally equally spaced at a distance of 150 - 300mm (6 12) from the low reading along the length of the CHS.
6.4.3
If one or more of these additional readings are also less than 80% of the specified thickness further readings should be taken to establish the extent of the low area. The whole area should then be brought up to the required thickness by application of more Firetex M93.
6.4.4 6.4.5
Individual thickness readings of less than 50% of the specified thickness are not acceptable. Maximum thickness of Firetex M93. Where Firetex M93 has been applied without the use of solvent thinning, application significantly above the required target value does not normally pose a problem. Since Firetex M93 may be specified at target DFTs from 4mm to 24mm (0.16 to 0.94) one can see that there is a wide scope for allowable variation in over application. For the purposes of providing some broad guidance, the average of all readings in the defined measurement area should not exceed the specified DFT by more than 10%. No individual reading in the defined measurement area should exceed the specified DFT by more than 50%. However, depending on the specified thickness, the method of application and the end use requirement, it may be possible to allow the average of all readings to exceed the specified DFT by a considerable margin. This must only be done with the clients permission by raising a variation request. They will in turn seek Leighs opinion.
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Product name Product Reference: Base Additive Colour/Color Batch number: Base Additive Thinners: Reference Vol. % added Panel Coat DFT No. No. (m or mils) #1 1 2 3 4 #2 1 2 3 4 #3 1 2 3 4 #4 1 2 3 4
Date applied
Application method
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Topcoat
Product type
General use
Splash / Immersion
Decks
Firetex M75
Modified PU
50 (2)
Resistex C137V2
Over-coatable PU
50 (2)
50* (2)*
Resistex C237V2
Over-coatable PU
50 (2)
Resistex K651
Aliphatic PU
50 (2)
Epigrip M262
Epoxy gloss
75 (3)
75* (3)*
Epigrip M922
400 (16)
Epidek M339
Epidek M153
All dry film thickness measurements are nominal - Topcoat type not applicable for that environment * Over M922 as a cosmetic coat
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Damaged Area removed & repair area ground to chamfered edges as shown, leaving existing Firetex H180 Scrim intact for overlap bonding.
Steel Plate
1st layer of Firetex M93 repair applied to the mid film position With Firetex M93, still wet. Apply the piece of Firetex H180 scrim to the repair area, with an overlap of min. 50mm (2) all round onto existing scrim. Note that where scrim is not required then there is no need to install a piece in these areas.
Final application of Firetex M93 to repair bringing up to final DFT of existing Firetex M93. Where scrim is not used then simply bring M93 up to final DFT of existing M93
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Outside the stated optimum environmental conditions the time required for curing of Firetex M93 prior to adhering dollies may need to be increased, and pull-off values may differ from those obtained under optimum conditions.
Where applied in conditions above 35C (95F) and 75% RH, Firetex M93 may exhibit a soft thermoplastic-like effect, which may result in reduced cohesive properties and pull-off adhesion readings. This delayed curing is to be expected and does not reduce the fire protection performance of the product. When ambient conditions return to stated requirements optimum cure will be achieved albeit over an extended period of time. Under such conditions pull-off adhesion testing is of little use for in-process testing and Shore D Hardness testing is preferred. Shore D testing can be used to monitor the development of cure with time and when a minimum value if 50 has been reached, fire resistance performance will be in-line with certification. Shore D testing shall be done in accordance with ISO 868:2003 using the method of taking the instantaneous maximum reading.
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PFP applied to beam and guides to achieve fire rating based on Hp/A (W/D) and fire scenario specified. Pipe shoe support may also fire protection in its own right. Note: Pipe support sliding face is left clear of PFP.
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5.2 Typical detail for sliding pipe support where top of beam is not exposed to fire or radiant heat, or is cooled by deluge
The design may be used where the top flange of the beam is not exposed to fire or radiant heat, or is cooled by deluge. The decision to fire protect this top face or not, is part of the safety case assessment and as such is the responsibility of the design team, not Leighs Paints. PFP applied to beam to achieve fire rating based on Hp/A (W/D) and fire scenario specified.
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5.3 Typical detail for fixed pipe support where top of beam is exposed to fire or radiant heat
PFP applied to beam and supports to achieve fire rating based on Hp/A (W/D) and fire scenario specified. Pipe support may need to be completely fireproofed or only coatback protected. If coatback then minimum 450mm (18) and thickness to be as per main beam. Note: Pipe support sliding face is left clear of PFP.
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PFP applied to beam and supports to achieve fire rating based on Hp/A (W/D) and fire scenario specified. Coatback protection only required when hanger cross-section is greater than 3000mm (4.65 sq. inch). Where coatback required distance is 450mm (18) and thickness to be as per main beam.
2
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In this design the deck grating is supported by the Firetex M93 and is suitable for general walkways. Firetex M93 should be rolled smooth and level.
The stud welding for the grating is done prior to application of Firetex M93 and masking sleeves used to protect these while Firetex M93 is applied. Alternatively cured Firetex M93 may be removed using a holesaw and Hilti XB-T fastenings installed & the hole repaired using Firetex M93.
Alternatively the grating can be filled with Firetex M93 above the flange but this uses excessive material and the grating will be firmly bonded to the beam and so no longer removable.
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6.2 Alternative detail for heavy duty protection of top of beam exposed to fire
In this design the deck grating is supported partly by the up-stand angle and the Firetex M93. The angles also provide a guide to level the Firetex M93 to a known thickness. This option allows for a greater load to be supported but a structural engineer must approve this. The stud welding for the grating is done prior to application of Firetex M93 and masking sleeves used to protect these while Firetex M93 is poured and levelled. Alternatively cured Firetex M93 may be removed using a hole-saw and Hilti XB-T fastenings installed & the hole repaired using Firetex M93.
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The principle of this design is to elevate the level of the grating above the top surface of the beam by ay approximately 12 to 15mm (0.48 to 0.6). This allows the beam to be fully protected, while allowing drainage through the grating. At the design stage the beam height is lowered by typically 12 15mm (0.48 to 0.6) and then Tee section is welded to the top flange, bringing the flange face back to the correct level. Loadings must be verified by a structural engineer.
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6. 4 Standard detail for unprotected top flange where it is not exposed to Fire and radiant heat, or is cooled by deluge
The design may be used where the top flange of the beam is not exposed to fire or radiant heat, or is cooled by deluge. The decision to fire protect this top face or not, is part of the safety case assessment and as such is the responsibility of the design team, not Leighs Paints. In cases where it is deemed that no fire protection is required on the top flange then the grating is installed as normal. It is general industry practice to use the 4-sided Hp/A (W/D) calculation to determine the PFP thickness, and use this thickness in the remaining three sides to provide a safety factor, although this is a decision to be made by the project team on a case by case basis.
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450 mm (18)
Primary member thickness as per certification based on Hp/A (W/D) and fire scenario
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450 mm (18)
Primary member thickness as per certification based on Hp/A (W/D) and fire scenario
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Secondary member
Primary CHS
Primary member thickness as per certification based on Hp/A (W/D) and fire scenario
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